Remote Terminal Units - Data sheet

DIN Rail RTU 540CID01

RTU540 product line

RTU540 base modul with 2 Ethernet ports

• Metal housing
• 4x serial port (RS-232 or RS-485)
• 2x Ethernet interface (10/100BaseT)
• USB configuration interface
• Power supply 24... 125 V DC (galvanic
isolated)
• Integrated I/O (16 binary inputs, 8 binary
outputs, 8 analog inputs)
• (1 out of n) check
• With connection interface to RTU500 I/O-
extension modules
• Battery buffered real time clock

Application The unit is available in two versions:

The 540CID01 is a module of the RTU540 product line • R0001: process voltage 24 ... 60 V DC
consisting of a communication unit (CMU), a multi-I/O • R0002: process voltage 110 ... 125 V DC
module (IOM) and a galvanic isolated wide range power
supply (PSM) in a metal DIN rail housing.
4 3 1 2 E1 E2
The essential tasks are: RS232C RS232C RS232C
10/100 MB LAN
or RS485 or RS485 or RS485
• Managing and controlling of the RTU520 I/O modules
via the serial I/O bus
UART
UART

• Reading Process events from the input modules.

• Send commands to the output modules. Protocol Protocol
• Communicating with control systems and local HMI Controller Controller
systems via the serial interface and the Ethernet
interfaces.
UART

UART
SPI
SPI

• Communication with Sub-RTU’s, IED’s or multimeter

devices via the serial interface and the Ethernet
interfaces. MPU
Cortex-A8
• Managing the time base for the RTU540 product line
AM3352
station and synchronizing the I/O modules.
• Handling the dialog between RTU540 product line and
UART

Web-Browser via the LAN and USB interfaces.

540IOM01 SPI DDR-III
• Capturing of 8 analog input signals (mA or V signals), I/O Controller SD Card
(IOC) FLASH SDRAM
fast scan cycle of 100 ms for 2 inputs
• Capturing of 16 digital input signals, 1 high speed
counter input (max. 16 kHz)
• 8 output contacts (normal open), 1 or 2 pole output
The unit has a battery buffered real time clock (RTC). USB 2.0 WRB 16BI 8BO 8AI
1 2
Figure 1: Function block diagram 540CID01
Characteristics
Communication unit
On the applied ARM cortex A8 controller AM3352 a real-
time operating system is implemented. The 540CID01
is responsible for the interface management, the event
handling, the time base and the internal data base. The
controller acts as master for the serial I/O bus (WRB).
System relevant configuration files are stored in the non-
volatile flash memory card (removable SD-card™) in order
to guarantee a valid system configuration after Power on
Reset (PoR).
• Threshold value monitoring on absolute value or with
accumulation
• Periodic transmission and background cycles
The module provides a data buffer for temporally storing
of up to 160 event messages including time stamps. The
events are stored in chronological order designated for
transmission to the communication unit (CMU).
During initialization and operation the module carries
out a number of tests. If a fault occurs it is reported to
the communication unit. All fault conditions impairing the
function of the module are displayed as common fault
signal by a red LED. A failure of the module is detected by
the communication unit.

A battery buffered RTC is used to keep an exact time

during power off state. Binary input unit

The communication unit provides the following interfaces:

• Communication Port 1 ... 4 (CP1 ... CP4): serial BI1
I01
C01
interfaces according RS232C or RS485 with RJ45 I02
BI2
connectors.
• Ethernet interface 1 and 2 (E1 & E2): 10/100BaseT BI3
I03

with RJ45 connector. I04

BI4
• USB 2.0 device interface for diagnosis and
maintenance purposes. BI5
I05

• USB 2.0 host interface for future extensions. I06

BI6
• WRB I/O bus interface for local communication with Micro-
the I/O-modules controller
BI7
I07

Input register
I08
RAM BI8
I/O controller (IOC)
I09
BI9
Flash C02
The micro-controller on the module processes all time
I10
BI10
critical tasks of the parameterized processing functions. IOC
Moreover it carries out the interactive communication with BI11
I11

the RTU I/O bus. All configuration data and processing

I12
BI12
parameters are loaded by the communication unit via the
RTU I/O bus. BI13
I13

The binary input unit can execute the following processing BI14
I14

functions for the different types of signals: I15

BI15
• Digital filtering to suppress contact bounce
• Suppression of oscillating signals caused by the BI16
I16

process
• Validity check and suppression of intermediate input
states for double indications Figure 2: Block diagram 540IOM01 binary input unit

• Consistancy check for all channels allocated to digital
measured values or step position information
• Summation of increment pulses to form integrated
totals in registers of 31 bit resolution
• Copying of integrated totals values into freezing
registers for data conservation
The binary output unit can execute the following
processing functions on the individual signal types:
• Control of the command output duration
Command monitoring functions:
• (m out of 8) check of the output relays on the module
• switching voltage monitoring (24 V DC coil voltage)
before and during output
• command output duration monitoring
The analog input unit can execute the following processing
functions on the measured values:
• Scan cycle and line frequency interference
suppression
• Zero value supervision and switching detection
• Smoothing
The module 540CID01 provides 16 galvanic isolated
inputs for up to 16 binary process signals. Scanning and
processing of the inputs are executed with the high time
resolution of 1 ms. The allocation of an input signal to the
processing functions can be done according to the rules of
configuration.
The module 540CID01 is able to process the following
types of signals or a combination of them:
• 16 single point information with time stamp (SPI)
• 8 double point information with time stamp (DPI)
• 2 digital measured values each with 8 bit (DMI8)
• 1 digital measured value with 16 bit (DMI16)
• 16 integrated totals (max. 120 Hz) (ITI), including 1
high speed counter (max. 16 kHz)
• 2 step position information each with 8 bit (STI)
• 2 bitstring input each with 8 bit (BSI8)
• 1 bitstring input with 16 bit (BSI16)
• or combinations of this signal types
The module is available in two versions (rubrics): The 8 differential inputs are not galvanic isolated against
• 540CID01 R0001: process voltage 24 to 60 V DC. the power supply.
LED signaling for each input, common return per 8
inputs. Single-ended or differential input values are resolved by
• 540CID01 R0002: process voltage 110 to 125 V DC. up to 4096 steps (12 bit plus sign) for 100 % measurement
LED signaling for each input, common return per 8 amplitude.
inputs.
The inputs are galvanic isolated by means of optical The differential inputs are protected against static and
couplers. 8 inputs are building a group with a common dynamic over-voltages by a protection circuit. A low-pass
return. The input circuit is designed to keep the input filter suppresses unwanted frequency components.
current constant by using current regulative diodes.
The internal high resolution of the AD converter allows to
The binary input channels are protected against reverse scan all measuring ranges with the same resolution.
voltage installation. If the input signal is installed with
For elimination of tolerances a calibration is done during
wrong polarity the input current will be zero.
production.
The module has 16 LEDs to indicate the signal state at the
The synchronization of the scan cycle with the line
inputs. The LEDs follow direct the input signal.
frequency is used to increase the line frequency
The maximum permissible frequency for counter pulses is interference suppression of the DC input signal.
120 Hz. The input BI1 can be used up to 16 kHz (at 50%
duty cycle). Frequency Conversion time Scan cycle time
per channel (same for all
channels)
Analog input unit
60 Hz 50 ms 400 ms (fast scan
AI1 & AI2: 100
ms)
+ AI8 50 Hz 60 ms 480 ms (fast scan
AI1 & AI2: 100
ms)
Resistor network
Protection

ADC
A 16.7 Hz 180 ms 1440 ms (fast
Micro -
controller scan AI1 & AI2:
- AI8 200 ms)
...
Multiplexer

RAM
Input circuit

Signal- +
AI3
Binary output unit
conditioning -
Flash
+ I02
Signal- +
conditioning - I02 AI2
D -
IOC
+ I01 +
Signal-
conditioning - I01 - AI1 R01 O01

R02 O02

R03 O03
Figure 3: Block diagram 540IOM01 anaolg input unit Micro -
Output register

controller
The 540CID01 module records up to 8 analog measured R04 O04

values. RAM
R05 O05

The module 540CID01 is able to process the following Flash

R06 O06
types of signals:
• Analog measured values (AMI) IOC
R07 O07

• Measured floating point information (MFI) Voltage

monotoring
R08 O08

Following measurement ranges can be configured:

• ± 2 mA
• ± 5 mA R17

• ± 10 mA
• ± 20 mA Output relay
control
24 V DC
• ± 40 mA
• ± 2 V DC Figure 4: Block diagram 540IOM01 binary output unit
• ± 20 V DC The module 540CID01 can be used for the control of 8
Other effective ranges and live zero signals become binary process signals using relay contacts. The allocation
generated out of these ranges through conversion of the of an output signal to the processing functions can be
communication unit (CMU). done according to the rules of configuration.

Basic signal checks and cyclic processing functions The module 540CID01 is able to process the following
are already be done locally in order to unburden the types of signals:
• Single or double commands (SCO or DCO) with 1 or 2
communication unit. The module transmits relevant
pole output without (1 out of n) check
changes as event via the RTU I/O bus.
• Single or double commands (SCO or DCO) with 1.5 or
2 pole output with (1 out of n) check
• Regulation step command (RCO), 1 or 2 pole
• Digital setpoints commands, 8 Bit without strobe Command relay (B01...B08 or on 520BOD01)
(1 out of n) check
(DSO8) Switch over from “CHECK“ to “SWITCH“

• Digital setpoint commands, 8 Bit with strobe (DSO8) Output pulse given by “GO“ relay
output pulse

• Bitstring output, 1, 2 or 8 Bit (BSO1, BSO2 or BSO8) (1 out of n) check period (with positive result)

The module allows switching voltages up to 250 V DC or

Figure 5: Time diagram of the (1 out of n) check circuit
max. 8 A continious current.
To ensure correct output the board carries out several
Relay contacts are used for the binary outputs. monitoring functions before and during command output:
• Monitoring of output duration and reset in case of fault
The 8 outputs are isolated from one another. All 8 relays • Monitoring of switching voltage before and during the
contacts have individual contacts without a common command output
return.
Main Supply Supervision (MSS)
The supply voltage for the coils of the relays (24 V DC)
is monitored internally before and during the command The monitoring function (MSS) is used to test and to
output. supervise Battery Voltage Supply units. MSS gives
the status that the Battery is in good condition and all
Two output relays are required for each command in case connections and fuses are OK. In case of a Failure or in a
of 2 pole commands. Warning situation The 540CID01 detects this at the MSS
input and generates a message.
Before and during command output the module 540CID01
carries out several command monitoring functions. These
tests ensure correct output. MSS input unit can detect 4 different states:
• Normal operation = High signal
If the command monitoring detects fault the command will • AC Failure = 0,5 Hz signal
be canceled. • Battery Failure = 2,0 Hz signal
• Wiring or Fuse Failure = Low signal
(1 out of n) check circuit If this MSS functionality is configured then the 540CID01
will report a Warning or Alarm situation to the central
The check circuit for measuring the resistance of the relay
station. In addition the 540CID01 can switch the ALARM-
coil is galvanic isolated against the other electronic voltage
output (X6) in case of any error.
and against the switching voltage (UP) of the interposing
relays.
Alarm Output (ALR)
The essential features are:
• Galvanic isolation of the check circuit done by If an error condition occurs in the RTU the ALR- output will
means of a galvanic isolated DC/DC-converter and be switched. RTU error conditions have to be taken from
optocouplers the function description of the RTU500 series releases.
• Suppression of line frequency during resistance
measuring
The (1 out of n) check of the 540CID01 module measures
the resistance value in the output circuit and compares
19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 4 3 2 1 7 6 5 4 3 2 1
+ - + - + - + -
I1 I2 I3 I4 I5 I6 I7 I8 C1 NC C2 I9 I10 I11 I12 I13 I14 I15 I16 MSS ALR CH6 CH7 CH8 NC

this value with the configured upper and lower limit

In

X5 X6 X7

values. If the resistance value is within the limits the BI SD C ard- ® AI

selected interposing relay can be activated. The object

command will be acknowledged positively. If the measured
resistance value is outside the tolerance limits the Figure 6: Top side of 540CID01 housing

540CID01 blocks the output and indicates the error to the

communication unit (CMU).

After one command relays (B01..B08 or on another

520BOD01) has switched on, the 540CID01 gets the
order to check and process the object command. The
540CID01 switches the output circuit to the check circuit
via the external "check" relay (R10). The resistance is
determined by the arising measuring circuit voltage by
output of a constant current. If the measured resistance
value is within the tolerance range, the "check" relay is
Figure 7: Front side of 540CID01 housing
switched. After that the external "GO" relay (R09) switches
the selected interposing relay and releases the object
command.
PPS BO AI

X1 X2 X3
PS
PE I/O GR MR 1-of-N O1 O2 O3 O4 O5 O6 O7 O8 CH1 CH2 CH3 CH4 CH5 NC
- + + - + - + - + - + - + -
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11

Figure 8: Bottom side of 540CID01

Technical data Signaling by LEDs
In addition to the RTU500 series general technical data,
ERR (red) ON: RTU in error state
the following applies:
Flashing: RTU in warning
state
Main Processing Unit MPU
CPU ARM cortex A8, AM3352 @ For more details see
800 MHz RTU500 series Function
Description
RAM 256 MByte
RUN (green) Communication module in
Boot Flash 8 MByte operation
PF (red) Failure of one of the internal
SD card voltages (24 V DC out not
included)
Connector SD card slot (push push)
I/O bus (green) Transmission on to the I/O
Type SD 2.0, class 2
bus
Capacity 4 GByte
T Transmit data on serial
communication ports CP
Real time clock RTC (Backup) R Receive data on serial
Battery Lithium 3 V DC, CR2032 communication ports CP
Time resolution 1 sec, 1ms with timesync S Ethernet communication
speed:
Battery lifetime > 10 years
Free running ± 50 ppm ON: 100 Mbit/s

OFF: 10 Mbit/s
Serial interfaces 1, 2, 3, 4 L Link up on Ethernet
Connector RJ45 interface E

Type RS232C or RS485

RS232C: Binary input channels 540CID01 R0001
Bit rate 200 bit/s - 38.4 kbit/s Inputs 16 channels,
Signal lines GND E2/102
common return for 2 groups
TxD D1/103
of 8 channels,
RxD D2/104
isolated by opto-couplers
RTS S2/105 Nominal input voltage 24... 60 V DC (+/- 20%)
CTS M2/106 Max. input voltage 72 V DC

DTR S1.2/108
Input current typ. 2 mA constant
Logical ‘1’ definitely ≥ 18 V DC
DCD M5/109 detected
Level typical: ± 6V Logical ‘0’ definitely ≤ 9 V DC
RS485: detected
Bit rate 200 bit/s - 38.4 kbit/s Reverse voltage protection yes
Level typical: ± 6V Max. input frequency for 120 Hz (high speed channel
integrated totals BI1: 16 kHz)
Ethernet interface E1 and E2
Connector RJ45 Binary input channels 540CID01 R0002
Type IEEE 802.3, 10/100BaseT Inputs 16 channels,

common return for 2 groups

USB interface 1 of 8 channels,
Connector USB Type A (for future
isolated by opto-couplers
extensions)
Nominal input voltage 110... 125 V DC (+/- 20%)
Type USB 2.0 host, low and full
speed (max. 12 MBit/s) Max. input voltage 152 V DC
Input current typ. 1,2 mA constant
USB interface 2 Logical ‘1’ definitely ≥ 80 V DC
detected
Connector USB Type B (configuration
interface) Logical ‘0’ definitely ≤ 45 V DC
detected
Type USB 2.0 device, low and full
speed (max. 12 MBit/s) Reverse voltage protection yes
Binary input channels 540CID01 R0002 Analog input channels 540CID01
Max. input frequency for 120 Hz (high speed channel Line frequency interference > 100 dB @ fN ±2 %
integrated totals BI1: 16 kHz) suppression
> 45 dB @ fN ±10 %

Binary output characteristics

Outputs 8 Relay contacts, Signaling by LEDs
single pole, normal open BI 16x (yellow) LED displays the active
Max. switching voltage 250 V DC inputs
Continuous current 8A BO 8x (yellow) LED displays the active
output relays
Max breaking current 8 A ≤ 55 V DC
(resistive load) 6 A @ 60 V DC
0.9 A @ 110 V DC
0.3 A @ 220 V DC ALR (Alarm Output)
Max. breaking capacity 50 VA (L/R= 40 ms) Alarm (ALR): Normal closed (NC),
(inductive load) isolated
Relay contact
Pulsed output current, 10 A @ 30 VDC
max. 30 seconds pulses Max. contact current: 8A
with 50% Duty Cycle Max. contact voltage: 250VDC
Max. switching power: 120W resistive

Analog input channels 540CID01 50W at L/R=40ms

Inputs 8 differential inputs
Configurable measuring • ± 2 mA
MSS (Main Supply Supervision)
range • ± 5 mA
MSS: 24V, 48V, 60VDC
• ± 10 mA
• ± 20 mA Digital Input: ≥ 18V = Logic 1
• ± 40 mA
• ± 2 V DC ≤ 9V = Logic 0
• ± 20 V DC Input current: 2mA constant
Input impedance 150 Ω @ ±2 to ±10 mA Over-voltage protection: 72VDC
Reverse voltage protection: yes
50 Ω @ ±20 and ±40 mA

110 kΩ @ ±2 and ±20 V DC

Max. load 80 mA continuous @ ±20 PPS (Process Power Supervision)
and ±40 mA Process voltage input: 24 / 48 / 60VDC (R0001)

40 mA continuous @ ±2 to PS (I/O): 110 / 125VDC (R0002)

±10 mA
38 V/ 0.5 mA @ ±2 and ±20
V DC
Resolution 12 bit + sign
11 bit + sign @ ±2 V DC
AD converter resolution 24 bit
Accuracy at 25 °C ≤ 0.1 %
≤ 0.2 % @ ±2 V DC
Linearity error at 25 °C ≤ 0.1 %
Temperature drift ≤ 100 ppm/K (0... 70 °C)
Max. common mode input ±150 V DC (electrical limit)
voltage
±8 V DC (functional limit)
Max. differential input ± 4 V DC (current input)
voltage
± 38 V DC (voltage input)
Common mode rejection > 70 dB @ 25 °C
> 60 dB @ 0… 25 °C
Configurable line frequency • 16.7 Hz
fN • 50 Hz
• 60 Hz
GO Relay (GR): Coil voltage: 24VDC, max.
0,1A
Meas Relay (MR): Coil voltage: 24VDC, max.
0,1A
Input current: 2mA constant
Over-voltage protection: Max. 72VDC (R0001)
Max. 152VDC (R0002)
Reverse voltage protection: yes
Power supply input
Input voltage 24 ... 125 V DC
Input tolerance range -20%... +20%
Max. input current 2A
Starting current <20 A; 50µs - 1.5ms
(Class S1 according to IEC
60870-4)
Efficiency 88% @24 V DC
Power consumption 8.7 W (0.1 A @ 24 V out)
Power supply input
External circuit-breaker
Reverse voltage protection
Galvanic isolated between
primary circuit and
secondary circuit
The plus lead has to be
protected by an upstream
circuit-breaker with 10 A
tripping current.
yes
yes
Insulation tests
AC test voltage 2.5 kV, 50 Hz
IEC 61000-4-16 Test duration: 1 min
IEC 60870-2-1 (class VW3)
Impulse voltage withstand 5 kV (1.2 / 50 µs)
test
IEC 60255-5
IEC 60870-2-1 (class VW 3)
Insulation resistance > 100 MΩ at 500 V DC
IEC 60255-5

Power supply output

Total output power 30 W
Immunity test
24 V DC power supply output Electrostatic discharge 8 kV air / 6 kV contact (level
Voltage 24 V DC (galvanic isolated) IEC 61000-4-2 3)

Tolerance ±20 % Performance criteria A

Max. current 500 mA Electrical fast transient / 4 kV (level 4)
Residual ripple ≤ 200 mVPP Burst
IEC 61000-4-4 Performance criteria A
Surge 4 kV (level 4)
Current supply for power supplied via WRB bus IEC 61000-4-5
5 V DC (±5 %) 1.8 A Performance criteria A
±15 V DC (±10 %) 200 mA Conducted disturbances, 10 V (level 3)
induced by radio-frequency
18 V DC (±20 %) 50 mA
fields Performance criteria A
IEC 61000-4-6

Mechanical layout Damped oscillatory wave 2.5 / 1 kV (level 3)

IEC 61000-4-18
Dimensions 204 mm x 105 mm x 90 mm Performance criteria A
(Width x Height x Depth)
Housing type Metal case
Mounting DIN rail mounting (EN Environmental conditions - climatic
50022 TS35: 35 mm x 15 Nominal operating temper- -25 °C ... 70 °C
mm or 35 mm x 7.5 mm) ature range
Enclosure protection class IP20 EN 60068-2-14
Weight ca. 1,3 kg Start up -40 °C
EN 60068-2-1
Relative humidity 5... 95 %
Connection type EN 60068-2-30 (non condensing)
Power Supply: 2 x 3 pole pluggable

screw terminals
Binary Input: 19 pole pluggable screw
terminals
Binary Output: 16 pole pluggable screw
terminals
(1 out of n) check: 7 pole pluggable screw
terminals
Analog Input: 11 and 7 pole pluggable
screw terminals
MSS / Alarm: 4 pole pluggable screw
terminals
IO- Interface: 1 x 20- pole

Wirde- OR- Interface: Pluggable connectors

Ethernet Interface E1 and RJ45 jack, 8 pole
E2:
Serial Interfaces 1, 2, 3, 4: RJ45 jack, 8 pole
 Ordering information
540CID01 R0001 1KGT037300R0001

process voltage 24 ... 60 V

DC
540CID01 R0002 1KGT037300R0002

process voltage 110 ... 125

V DC

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